High-efficient blasting erosion arc sawing of diamond/Al composite

Diamond/Al composites are increasingly valued for their excellent thermal conductivity, making them crucial in various applications such as telecommunications and aerospace. However, traditional machining methods encounter significant challenges for the existence of extra hard diamond reinforcements. Blasting erosion arc machining (BEAM), known for its high efficiency from the high temperature, high energy utilization ratio, and high energy density, offers a promising solution for processing difficult-to-cut materials. In this study, blasting erosion arc sawing (BEAS) is utilized to cut diamond/Al composites efficiently. A multi-physics simulation model based on Magnetohydrodynamics (MHD) theory is developed to reveal the workpiece material removal mechanism by analyzing the temperature and distribution during discharge. Furthermore, fluid flow simulations indicate that a high-speed rotating electrode drives fluid flow, effectively deflecting the arc plasma and flushing the debris particles away. Experiment results demonstrate that when processing 20 vol% diamond/Al composites, BEAS can achieve an area cutting speed of 115.08 mm²/min while maintaining a surface roughness of 18.87 μm.